Buss bar strip

ABSTRACT

A buss bar strip for mounting to a solar panel to electrically connect to a series of electrical lines extending from solar cells. The buss bar strip can include a thin elongate flat flexible strip of insulative material having a longitudinal length. A predetermined pattern of elongate conductors can be longitudinally disposed on the insulative strip in at least two rows along the longitudinal length and electrically isolated from each other. Each conductor can have a predetermined position, length, and spacing from each other on the insulative strip for laterally electrically connecting to selected electrical lines from the solar cells at lateral electrical connection points located along the length of the conductor on exposed surfaces on the conductor.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/841,700, filed on Aug. 31, 2006, U.S. Provisional Application No.60/849,633, filed on Oct. 5, 2006 and U.S. Provisional Application No.60/920,382, filed on Mar. 28, 2007. The entire teachings of the aboveapplications are incorporated herein by reference.

BACKGROUND

Solar cells on a solar panel are typically electrically connected to aseries of conductors located at the edge of the solar panel. Theconductors are cut to length, installed within the solar panel, andsoldered by hand to make the necessary electrical connections. This is alabor intensive process.

SUMMARY

The present invention provides a buss bar conductor strip or assemblywhich can reduce the amount of labor required for making electricalconnections to the solar cells of a solar panel and to exterior cables.

The present invention can provide a buss bar strip for mounting to asolar panel to electrically connect to a series of electrical linesextending from solar cells. The buss bar strip can include a thinelongate flat flexible strip of insulative material having alongitudinal length. A predetermined pattern of elongate conductors canbe longitudinally disposed on the insulative strip in at least two rowsalong the longitudinal length and electrically isolated from each other.Each conductor can have a predetermined position, length, and spacingfrom each other on the insulative strip for laterally electricallyconnecting to selected electrical lines from the solar cells at lateralelectrical connection points located along the length of the conductoron exposed surfaces of the conductor.

In particular embodiments, the insulative strip can be formed ofpolymeric material. The series of elongate conductors can includegenerally flat ribbons of copper material laminated to the insulativestrip. The flat ribbons of copper material can be coated with a layer ofsolder. At least some of the conductors can be longitudinally staggered.The pattern of conductors can include an electrical connection regionfor electrically connecting to an external device. The electricalconnection region can be at a central location on the buss bar strip.Terminal pads can extend from the elongate conductors at the electricalconnection region. A male circular connector can be soldered to eachterminal pad. The series of elongate electrical conductors can includeat least four elongate conductors extending from the electricalconnection region. At least two can extend on one side and at least twocan extend on an opposite side. On each side of the electricalconnection region, one conductor can be shorter than the other. In someembodiments, the insulative strip can be a first insulative strip andthe buss bar strip can further include a second thin elongate flatflexible strip of insulative material laminated to the first strip andover the pattern of conductors. The second strip can have access windowsat selected locations for providing lateral electrical connection pointson the conductors.

The present invention can also provide a buss bar strip for mounting toa solar panel to electrically connect to a series of electrical linesextending from solar cells. The buss bar strip can include a thinelongate flat flexible strip of insulative material having alongitudinal length. A predetermined pattern of elongate conductor meansfor conducting electricity can be longitudinally disposed on theinsulative strip in at least two rows along the longitudinal length andelectrically isolated from each other. Each conductor means forconducting electricity can have a predetermined position, length, andspacing from each other on the insulative strip for laterallyelectrically connecting to selected electrical lines from the solarcells at lateral electrical connection points located along the lengthof the conductor on exposed surfaces on the conductor.

The present invention can also provide a solar panel including a seriesof solar cells having a series of electrical lines extending therefromat laterally spaced intervals. A buss bar strip can be mounted to thesolar panel adjacent to the series of solar cells and electricallyconnected to the series of the electrical lines extending from the solarcells. The buss bar strip can include a thin elongate flat flexiblestrip of insulative material having a longitudinal length. Apredetermined pattern of elongate conductors can be longitudinallydisposed on the insulative strip in at least two rows along thelongitudinal length and electrically isolated from each other. Eachconductor can have a predetermined position, length, and spacing fromeach other on the insulative strip and can be laterally electricallyconnected to selected electrical lines from the solar cells at lateralelectrical connection points located along the length of the conductoron exposed surfaces on the conductor.

In particular embodiments, the insulative strip can be formed offlexible polymeric material. The series of elongate conductors caninclude generally flat ribbons of copper material laminated to theinsulative strip. The flat ribbons of copper material can be coated witha layer of solder. At least some of the conductors can be longitudinallystaggered. The pattern of conductors can include an electricalconnection region for electrically connecting to an external device. Theelectrical connection region can be at a central location on the bussbar strip. Terminal pads can extend from the elongate conductors at theelectrical connection region. A male circular connector can be solderedto each terminal pad. The series of elongate electrical conductors caninclude at least four elongate conductors extending from the electricalconnection region. At least two can extend on one side and at least twocan extend on an opposite side. On each side of the electricalconnection region, one conductor can be shorter than the other.Lamination materials can extend over the buss bar strip. The externaldevice can be an electrical connector having female terminals thatengage the male circular connectors. In some embodiments, the insulativestrip can be a first insulative strip. The buss bar strip can include asecond thin elongate flat flexible strip of insulative materiallaminated to the first strip and over the pattern of conductors. Thesecond strip can have access windows at selected locations for providinglateral electrical connection points on the conductors.

The present invention can also provide a solar panel including a seriesof solar cells having a series of electrical lines extending therefromat laterally spaced intervals. Buss bar strip means for conductingelectricity can be mounted to the solar panel adjacent to the series ofsolar cells and electrically connected to the series of electrical linesextending from the solar cells. The buss bar strip can include a thinelongate flat flexible strip of insulative material having alongitudinal length. A predetermined pattern of elongate conductor meansfor conducting electricity can be longitudinally disposed on theinsulative strip in at least two rows along the longitudinal length andelectrically isolated from each other. Each conductor means forconducting electricity can have a predetermined position, length, andspacing from each other on the insulative strip and can be laterallyelectrically connected to selected electrical lines from the solar cellsat lateral electrical connection points located along the length of theconductor on exposed surfaces on the conductor.

The present invention can also provide a method of forming a buss barstrip for mounting to a solar panel for electrically connecting to aseries of electrical lines extending from solar cells. A thin elongateflat flexible strip of insulative material having a longitudinal lengthcan be provided. A predetermined pattern of elongate conductors can belongitudinally disposed on the insulative strip in at least two rowsalong the longitudinal length and electrically isolated from each other.Each conductor can have a predetermined position, length, and spacingfrom each other on the insulative strip for laterally electricallyconnecting to selected electrical lines from the solar cells at lateralelectrical connection points located along the length of the conductoron exposed surfaces of the conductor.

In particular embodiments, the insulative strip can be formed fromflexible polymeric material. The series of elongate conductors can beformed from generally flat ribbons of copper material laminated to theinsulative strip. The flat ribbons of copper material can be coated witha layer of solder. At least some of the conductors can be longitudinallystaggered. The pattern of conductors can be formed to include anelectrical connection region for electrically connecting to an externaldevice. The electrical connection region can be positioned at a centrallocation on the buss bar strip. Terminal pads can extend from theelongate conductors at the electrical connection region. A male circularconnector can be soldered to each terminal pad. The series of elongateelectrical conductors can include at least four elongate conductorsextending from the electrical connection region. At least two conductorscan extend on one side and at least two conductors can extend on anopposite side. On each side of the electrical connection, one conductorcan be shorter than the other. In some embodiments, the insulative stripcan be a first insulative strip. The buss bar strip can include a secondthin elongate flat flexible strip of insulative material laminated tothe first strip and over the pattern of conductors. The second strip canhave access windows at selected locations for providing lateralelectrical connection points on the conductors.

The present invention can also provide a method of electricallyconnecting a solar panel. The solar panel can include a series of solarcells having a series of electrical lines extending therefrom atlaterally spaced intervals. A buss bar strip can be mounted to the solarpanel adjacent to the series of solar cells. The buss bar strip caninclude a thin elongate flat flexible strip of insulative materialhaving a longitudinal length. A predetermined pattern of elongateconductors can be longitudinally disposed on the insulative strip in atleast two rows along the longitudinal length and electrically isolatedfrom each other. Each conductor can have a predetermined position,length, and spacing from each other on the insulator strip and can belaterally electrically connected to selected electrical lines from thesolar cells at lateral electrical connection points located along thelength of the conductor on exposed surfaces on the conductor.

In particular embodiments, the insulative strip can be formed fromflexible polymeric material. The series of elongate conductors can beformed from generally flat ribbons of copper material laminated to theinsulative strip. The flat ribbons of copper material can be coated witha layer of solder. At least some of the conductors can be longitudinallystaggered. The pattern of conductors can include an electricalconnection region for electrically connecting to an external device. Theelectrical connection region can be positioned at a central location onthe buss bar strip. Terminal pads can extend from the elongateconductors at the electrical connection region. A male circularconnector can be soldered to each terminal pad. The series of elongateelectrical conductors can include at least four elongate conductorsextending from the electrical connection region. At least two conductorscan extend on one side and at least two conductors can extend on anopposite side. On each side of the electrical connection region, oneconductor can be shorter than the other. Lamination materials can belaminated over the buss bar strip. The external device can be anelectrical connector having female terminals which can engage with themale circular connectors. In some embodiments, the insulative strip canbe a first insulative strip. The buss bar strip can include a secondthin elongate flat flexible strip of insulative material laminated tothe first strip and over the patter of conductors. The second strip canhave access windows at selected locations for providing lateralelectrical connection points on the conductors.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particulardescription of example embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingembodiments of the present invention.

FIG. 1 is a plan view of a rear portion of a solar panel having anelectrical connector attached to a buss bar conductor strip or assembly.

FIG. 2 is a bottom view of the electrical connector.

FIG. 3 is a partial sectional view of the electrical connector.

FIG. 4 is a rear plan view of a solar panel with an electrical connectorelectrically connected to a buss bar conductor strip or assembly.

FIG. 5 is an enlarged view of the electrical connector connected to thebuss bar strip of FIG. 4.

FIG. 6 is a plan view of a rear portion of a solar panel with the bussbar strip of FIG. 4 positioned in another orientation.

FIG. 7 is a plan view of the buss bar strip of FIG. 6.

FIG. 8 is an enlarged view of the electrical connector region of thebuss bar strip of FIG. 7.

FIG. 9 is a side view of the buss bar strip of FIG. 7.

FIG. 10 is a plan view of the buss bar strip of FIG. 7 without malecircular button connectors.

FIG. 11 is an enlarged view of the electrical connector region of FIG.10.

FIG. 12 is a cross sectional view of the buss bar strip of FIG. 7.

FIG. 13 is a plan view of another embodiment of a buss bar conductorstrip or assembly.

FIG. 14 is a schematic drawing of a method of manufacturing the buss barstrip of FIG. 13.

FIG. 15 is a plan view of another embodiment of a buss bar conductorstrip or assembly.

FIG. 16 is a plan view of yet another buss bar conductor strip orassembly.

FIG. 17 is an enlarged view of the electrical connector region of thebuss bar strip of FIG. 16.

FIG. 18 is a rear plan view of another solar panel having embodiments ofbuss bar conductor strips or assemblies.

FIG. 19 is a rear plan view of another solar panel having otherembodiments of buss bar conductor strips or assemblies.

FIG. 20 is a perspective view of an interior of another embodiment of anelectrical connector with some components removed for clarity.

DETAILED DESCRIPTION

Referring to FIGS. 1-5, solar panel 10 has a series of solar cells 12positioned side by side in a series of columns 12 a and rows 12 b. Thesolar cells 12 can be electrically connected to a series of electricalconductors 26 on a buss bar conductor strip or assembly 22 that can bepositioned on the solar panel 10, typically on the rear or backside ofthe solar panel 10 at an electrical conductor region 14 along an edge ofthe solar panel 10 by a series of electrical lines, wires, cables orconductors 24 extending from the solar cells 12. The buss bar strip 22can have an electrical connection region 28 with electrical terminalconnectors 30 where an electrical connector or connector assembly 16 canbe electrically connected to the buss bar strip 22. The electricalconnectors 30 can be male circular button connectors (FIG. 9).

The body 16 a of the electrical connector 16 can have an electricalconnection region 18 which can include a series of electrical terminalconnectors 18 a, for example resilient female terminal circular socketconnectors with resilient tabs 18 b arranged in a circular pattern forengaging the male connectors 30. The male connectors 30 can have agenerally planar circular base 30 a and a post 30 b (FIG. 9) with acircular cross section. The post 30 b can be angled slightly outwardsfor maintaining engagement with the female connectors 18 a. The femaleconnectors 18 a can be similar to those disclosed in U.S. Pat. No.6,520,812, the contents of which are incorporated herein by reference inits entirety. In addition, the male connectors 30 can be similar tothose disclosed in U.S. Pat. No. 6,475,043, the contents of which areincorporated herein by reference in its entirety. Alternatively,connectors 30 and 18 a can be other suitable types of mating connectors,and the buss bar strip 22 can have female connectors and the electricalconnector can have male connectors.

The electrical connector 16 can include electrical cables 20 extendingfrom the body 16 a for electrical connection to desired locations,including for example, connection to other solar panels in parallel orseries. The electrical connector 16 can include circuitry 19 positionedwithin the body 16 a capable of electrically bypassing damaged or shadedregions of the solar panel 10. Some embodiments can include bypassdiodes 17. The electrical connector 16 can have various configurationsand shapes, and can be similar to those described in U.S. patentapplication Ser. No. 11/803,017, filed May 11, 2007, the contents ofwhich are incorporated herein by reference in its entirety.Alternatively, other suitable electrical connectors or connectorassemblies can be employed. It is understood that the number andarrangement of connectors 30 and 18 a can vary, depending upon thesituation at hand.

Referring to FIGS. 4-6, the buss bar strip 22 can be presized with apredetermined series 26 of electrical conductors for electricalconnection to a particular solar panel 10 in a desired configuration.The buss bar strip 22 can be positioned, secured, or adhered withadhesives onto the back of the solar panel 10 at the electricalconductor region 14 along the edge of the solar panel 10. The electricallines 24 from the solar cells 12 can then be electrically connected orsoldered to lateral electrical connection points 25 on the buss barstrip 22. The buss bar strip 22 can be generally flat or planar with alow profile and can be later laminated to the solar panel 10 underlaminating materials which can include polymeric materials such as ethylvinyl acetate (EVA), and can also include or be laminated with a backingsuch as a polyvinyl fluoride (PVF) backing or glass 11. A hole can beformed in the laminating materials around the electrical connectionregion 28 to provide access for the electrical connector 16.

Referring to FIGS. 7-12, the buss bar strip 22 can include apredetermined pattern or series 26 of elongate electrical conductorswhich can be laminated between two elongate strips 32 of electricallyinsulative material, such as thin flat flexible strips or ribbons ofpolymeric or plastic material. The insulative strips 32 can be formed ofa variety of suitable materials, including for example, polyimide,polyvinyl acetate, etc. Flexibility of the insulative strips 32 canallow the buss bar strip 22 to conform to slightly uneven surfaces. Thepattern 26 of conductors and the insulative strips 32 can be laminatedtogether with a layer of adhesive 27. Alternatively, lamination can beaccomplished by heat or ultrasonic sealing. The pattern 26 of conductorscan be arranged spaced, sized and positioned in a predetermined mannerto electrically connect the solar cells 12 of the solar panel 10 in adesired or particular manner to form multiple zones or circuits,typically at least two, so that particular zones can be bypassed ifshaded or contain a damaged solar cell 12.

For example, the pattern 26 can include two rows with two long orelongate generally flat or low profile conductors 26 a positioned orspaced apart in series within the insulative strips 32 along a firstconductor axis A₁, and two short or elongate generally flat or lowprofile conductors 26 b positioned or spaced apart in series within theinsulative strips 32 along a second conductor axis A₂ that is parallelto axis A₁. Each of the conductors 26 a and 26 b can be positioned onopposite sides S₁ and S₂ of a central or middle axis M in a symmetricalmanner, for example, in mirror image. The conductors 26 a can extendlongitudinally beyond conductors 26 b in a staggered manner. Theconductors 26 a can longitudinally extend along axis A₁ from theelectrical connection region 28 in opposite directions and terminateclose to the ends of the insulative strips 32 on opposite sides S₁ andS₂ for laterally electrically connecting to electrical lines 24 of solarcells 12 in columns C₁ and C₄ (FIG. 6). The conductors 26 b canlongitudinally extend along axis A₂ from the electrical connectionregion 28 in opposite directions and terminate a shorter distance onopposite sides S₁ and S₂, for example, about the distance of a solarcell 12, for laterally electrically connecting to the electrical lines24 of the solar cells 12 in columns C₂ and C₃. The electrical lines 24can extend to the buss bar strip 22 in a transverse or orthogonal mannerrelative to conductors 26 a and 26 b. One of the insulative strips 32 a,such as the upper or top insulative strip 32 a, can include accessopenings or windows 25 a to allow the electrical lines 24 to beelectrically connected to the conductors 26 a and 26 b at selectedlateral electrical connection points 25 on exposed surfaces of theconductors 26 a and 26 b, which can be at right angle junctions with theconductors 26 a, 26 b, along axes A₁, and A₂. The longitudinallystaggered positioning of the spaced conductor pairs 26 a and 26 brelative to each other on each side S₁ and S₂ can allow electricalconnection of columns C₁ through C₄ to conductors 26 a and 26 b in anorganized and efficient manner, from the side or laterally, orthogonalor transverse relative to the buss bar strip 22, along the longitudinallength of the buss bar strip 22. The top insulative strip 32 a havingthe access windows 25 a can allow the buss bar strip 22 to be positionedeither in the orientation depicted in FIG. 4, or the orientationdepicted in FIG. 6. In the orientation depicted in FIG. 4, theelectrical lines 24 can cross over conductors 26 a to reach conductors26 b at lateral electrical connection points 25, since the topinsulative strip 32 a can electrically isolate the electrical lines 24from the conductors 26 a that are crossed. In some embodiments, morethan one buss bar strip 22 can be employed for electrically connectingto the electrical lines 24 on one side of the solar panel 10, and can bestacked or positioned on top of each other. For example, the lower orbottom insulative strip 32 b of one buss bar strip 22 can cover the topinsulative strip 32 a of another buss bar strip 22.

The conductors 26 a and 26 b can be formed of elongate metallic ribbonstrips, for example, copper or copper alloy material, that are laminatedto the insulative strips 32. The conductors 26 a and 26 b have a widthand thickness or cross section that is suitable for carrying current andpower from the solar cells 12. For example, the conductors 26 a and 26 bcan be about 3 mm to 5 mm (0.11 inches to 0.2 inches) wide, and about0.24 mm to 0.6 mm (about 0.009 inches to 0.024 inches) thick. Theconductors 26 a and 26 b can be spaced apart from each other by about 6mm (or about 0.25 inches). The conductors 26 a and 26 b can include alayer of solder 29 (FIG. 12) formed on one or both surfaces, forexample, the top surface, to allow quick and easy soldering to theelectrical lines 24. Alternatively, solder can be applied at the time ofsoldering. The insulative strip 32 can be low profile and can be about0.004 inches thick and have a width ranging from about 1 to 2 inches.The edge of the buss bar strip 22 can be positioned about 0.1 inchesaway from the solar cells 12 when positioned on the solar panel 10. Thedimensions can vary depending upon the situation at hand.

Referring to FIGS. 10 and 11, the conductors 26 a and 26 b can includeterminal pads 34 positioned in the electrical connection region 28 forelectrically connecting to an electrical connector 16. The terminal pads34 can be generally circular in shape and can be integrally formed andpositioned at the ends of the conductors 26 a and 26 b symmetricallyabout axis M. The base 30 a of the male connectors 30 can be soldered tothe terminal pads 34. The male connectors 30 can be in a desired patternfor electrically connecting to electrical connector 16 and can protrudethrough openings 34 a in one insulative strip 32, for example the topinsulative strip 32 a. Alternatively, the terminal pads 34 can belocated at intermediate portions of conductors 26 a and 26 b and canhave other shapes, or can be merely a location on the conductors 26 aand 26 b for soldering to male connectors 30. In addition, electricalwires, lines or cables can be directly soldered to the terminal pads 34or selected locations on conductors 26 a and 26 b for electricallyconnecting to a desired electrical connector, junction or location. Itis understood that the positioning or pattern of the male connectors 30and/or terminal pads 34 within the electrical connection region 28 canvary depending upon the configuration of the mating electrical connector16, or type of electrical connection. Referring to FIG. 12, in someembodiments, the bottom insulative strip 32 b can be covered by apressure sensitive layer of adhesive 31 which can be covered by a layerof release paper 31 a. The release paper 31 a can be removed allowingthe buss bar strip 22 to be adhered to the solar panel 10.

If desired, in some embodiments, the top insulative layer 32 a can beomitted, for example, as seen in FIG. 13. Buss bar conductor strip orassembly 22 a has only a single insulative strip 32, for example, abottom insulative strip 32 b, on which the pattern 26 of conductors islaminated. As a result, one side of the conductors 26 a and 26 a, forexample the top, can be exposed for lateral electrical connection toelectrical lines 24 at selected lateral electrical connection points 25.Longitudinal staggering or extension of the conductors 26 a beyondconductors 26 b provides lateral electrical connection access toelectrical lines 24 to both conductors 26 a and 26 b. Male connectors 30can be omitted as shown, or alternatively, male connectors 30 can besoldered to the terminal pads 34.

FIG. 14, depicts a process for forming a buss bar strip with anapparatus 35, for example, buss bar strip 22 a. A laminate 37 includinga strip of insulative material 32 and a metallic ribbon 36, for examplesolder clad copper or copper alloy material, can be fed into a die 38.The laminate 37 can include an adhesive 27 for bonding the strip 32 andribbon 36 together. The die 38 can cut the ribbon 36 into a repeatingpredetermined pattern 26 of conductors without cutting the insulativestrip 32. The pattern 26 of conductors can include terminal pads 34 ifdesired. The die 38 can be a rotary die, or alternatively, can be avertical press die. The adhesive employed for the laminate 37 can be ofa type that can allow the unwanted portions of the metallic ribbon 36 tobe removed. Station 39 can cut the buss bar strip 22 a to length. Ifdesired, a top insulative strip 32 a can be also laminated and windows25 and 34 a can be cut through one of the strips 32 to form buss barstrip 22. Furthermore, if desired, male connectors 30 can be soldered tothe terminal pads 34. In other embodiments, the pattern 26 of conductorscan be formed by other suitable means, for example, by deposition,printing or by directly applying metal ribbons or strips on the strip 32of insulative material in the desired pattern 26.

Referring to FIG. 15, buss bar conductor strip or assembly 40 differsfrom buss bar strip 22 a in that buss bar strip 40 includes conductors26 a and 26 b with terminal pads 34 on opposite ends. The terminal pads34 can allow electrical wires, lines or cables, and/or male connectors30 to be soldered to selected terminal pads 34. The additional terminalpads 34 can allow the buss bar strip 40 to be electrically connected toa solar panel 10 in a different manner than buss bar strip 22 a to formdifferent electrical circuit zones on solar panel 10, or to providedifferent features or options. Electrical lines 24 from the solar cells12 can lie on and be laterally soldered to desired intersectingconductors 26 a and 26 b. Typically, the electrical lines 24 areconnected to conductors 26 b close to center of the buss bar strip 40,and to conductors 26 a near the ends of the buss bar strip 40. Ifdesired, a top insulative strip 32 a can be included.

Referring to FIGS. 16 and 17, buss bar conductor strip or assembly 50differs from buss bar strip 22 a in that the pattern 26 of conductorscan include a series of conductors 26 a, 26 b and 26 c positioned in aspaced manner generally adjacent to each other in rows along threeparallel longitudinal axes A₁, A₂ and A₃, and symmetrically aboutcentral axis M. The conductor 26 c can be one continuous or singleconductor generally extending the longitudinal length of the buss barstrip 50. The conductor 26 c and the two pairs of conductors 26 a and 26b each can have a terminal pad 34 located in the electrical connectorregion 28, resulting for example, in a total of five terminal pads 34.The insulative strip 32 can include a widened portion 52 centered aboutaxis M at about the midpoint of the buss bar strip 50, which can be, forexample, generally circular in shape as shown. In other embodiments, thewidened portion 52 can have other suitable shapes, for example,rectangular, polygonal, nonsymmetrical curves, or combinations thereof.The widened portion 52 can allow the terminal pads 34 of the electricalconnection region 28 to be spaced apart from each other in the desiredspacing and pattern for electrically connecting to a desired associatedelectrical connection or mating electrical connector or connectorassembly. The conductors 26 b can have angled, bent or redirected legs51 for positioning the associated terminal pads 34 in the desiredlocations or patterns. Male connectors 30 can be soldered to theterminal pads 34 if desired. The buss bar strip 50 can be electricallyconnected to a solar panel 10 in a similar manner as buss bar assembly22 a if only conductors 26 a and 26 b are employed, or can be connectedwith additional circuitry features or options or zones employingconductor 26 c and its associated terminal pad 34.

Referring to FIG. 18, solar panel 10 is shown to have six columns 12 aof solar cells 12 in comparison to the four columns 12 a, depicted inFIGS. 1, 4 and 6, and includes two buss bar conductor strips orassemblies 60 and 62 at opposite ends of the solar panel 10. Buss barstrip 60 is similar to buss bar strip 22 a, differing in that buss barstrip 60 and conductors 26 a can be longer in length in order for eachconductor 26 a to laterally electrically connect to electrical lines 24from an additional column 12 a of solar cells 12. The buss bar strip 62can laterally electrically connect to electrical lines 24 from the solarcells 12 to complete the circuit at the opposite end of the solar panel10 in the desired circuit configuration. Buss bar assembly 62 does nothave an electrical connection region 28 and can have a pattern 26 ofelectrical conductors with a single long conductor 26 c and two spacedshorter conductors 26 b in series to each other and parallel to theconductor 26 c on sides S₁ and S₂, symmetrically about axis M. Dependingupon the desired manner of electrically connecting the solar cells 12,and the internal circuitry of the electrical connector that mates orconnects to the male connectors 30 at the electrical connection region28, buss bar strips 60 and 62 can have different configurations thanshown. The buss bar strips 60 and 62 can be adhered to the back of solarpanel 10 on opposite sides of the solar cells 12 at electrical conductorregions 14 and electrically connected in the desired or predeterminedmanner to electrical lines 24 at electrical connector points 25 in alateral, orthogonal or transverse manner. The buss bar assemblies 60 and62 and the back of the solar cells 12 can be covered and sealed withlaminating materials and glass 11.

Referring to FIG. 19, a buss bar strip or assembly 70 can be mounted toa solar panel 10 and electrically connected to the electrical lines 24.Buss bar assembly 70 differs from buss bar assembly 60 in thatelectrical leads, cables, wires or conductors 72 can be electricallyconnected or soldered to the conductors 26 a and 26 b at the electricalconnection region 28 for electrically connecting to a junction box.

Referring to FIG. 20, electrical connector or connector assembly 80 isan example of another embodiment of an electrical connector forelectrically connecting to the electrical connection region 28 on a bussbar strip or assembly. Electrical connection region 18 of the electricalconnector 80 can include a series of terminals 86 having femaleelectrical connectors 18 a. The terminals 86 can have conductors 87which can be connected together in a desired circuit 90 including diodes88, for bypassing selected regions of the solar panel 10 containingsolar cells 12 that are shaded or damaged. The electrical connector 80can also include circuitry if desired for additional functions orfeatures. The electrical connectors 18 a can be electrically connectedto cables 20. It is understood that the configurations of the electricalconnectors or connector assemblies and buss bar conductor strips orassemblies vary depending upon the size of the solar panel 10, and thedesired manner of electrically connecting the solar cells 12 together.For example, the number and pattern of connectors 18 a and 30 can vary.

While this invention has been particularly shown and described withreferences to example embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims.

For example, features of the buss bar strips and electrical connectorsdescribed, can be omitted or combined together. In addition, buss barstrips having one insulative strip 32 can also be stacked. Furthermore,although the conductors on the buss bar strips have been shown to be ina generally symmetrical pattern, in some embodiments, the conductors canbe arranged in a nonsymmetrical manner and the electrical connectionregion 28 can be at non central locations, for example, at or near oneend. A top insulative strip 32 a with appropriately positioned accesswindows 2 a can allow such non symmetrical arrangements or can allow theuse of parallel conductors of the same length. Also, the pattern ofconductors can be embedded in the insulative strip(s).

1. A buss bar strip for mounting to a solar panel to electrically connect to a series of electrical lines extending from solar cells comprising: a thin elongate flat flexible strip of insulative material having a longitudinal length; and a predetermined pattern of elongate conductors longitudinally disposed on the insulative strip in at least two rows along the longitudinal length and electrically isolated from each other, each conductor having a predetermined position, length, and spacing from each other on the insulative strip for laterally electrically connecting to selected electrical lines from the solar cells at lateral electrical connection points located along the length of the conductor on exposed surfaces on the conductor.
 2. The buss bar strip of claim 1 in which the insulative strip is formed of flexible polymeric material.
 3. The buss bar strip of claim 2 in which the series of elongate conductors comprise generally flat ribbons of copper material laminated to the insulative strip.
 4. The buss bar strip of claim 3 in which the flat ribbons of copper material are coated with a layer of solder.
 5. The buss bar strip of claim 4 in which at least some of the conductors are longitudinally staggered.
 6. The buss bar strip of claim 5 in which the pattern of conductors include an electrical connection region for electrically connecting to an external device.
 7. The buss bar strip of claim 6 in which the electrical connection region is at a central location on the buss bar strip.
 8. The buss bar strip of claim 7 further comprising terminal pads extending from the elongate conductors at the electrical connection region.
 9. The buss bar strip of claim 8 further comprising a male circular connector soldered to each terminal pad.
 10. The buss bar strip of claim 7 in which the series of elongate electrical conductors include at least four elongate conductors extending from the electrical connection region, at least two extending on one side, and at least two extending on an opposite side.
 11. The buss bar strip of claim 10 in which on each side of the electrical connection region, one conductor is shorter than the other.
 12. The buss bar strip of claim 1 in which the insulative strip is a first insulative strip, the buss bar strip further comprising a second thin elongate flat flexible strip of insulative material laminated to the first strip and over the pattern of conductors, the second strip having access windows at selected locations for providing lateral electrical connection points on the conductors.
 13. A buss bar strip for mounting to a solar panel to electrically connect to a series of electrical lines extending from solar cells comprising: a thin elongate flat flexible strip of insulative material having a longitudinal length; and a predetermined pattern of elongate conductors means for conducting electricity longitudinally disposed on the insulative strip in at least two rows along the longitudinal length and electrically isolated from each other, each conductor means for conducting electricity having a predetermined position, length, and spacing from each other on the insulative strip for laterally electrically connecting to selected electrical lines from the solar cells at lateral electrical connection points located along the length of the conductor on exposed surfaces on the conductor.
 14. A solar panel comprising: a series of solar cells having a series of electrical lines extending therefrom at laterally spaced intervals; and a buss bar strip mounted to the solar panel adjacent to the series of solar cells and electrically connected to the series of electrical lines extending from the solar cells, the buss bar strip comprising a thin elongate flat flexible strip of insulative material having a longitudinal length, and a predetermined pattern of elongate conductors longitudinally disposed on the insulative strip in at least two rows along the longitudinal length and electrically isolated from each other, each conductor having a predetermined position, length, and spacing from each other on the insulative strip and laterally electrically connected to selected electrical lines from the solar cells at lateral electrical connection points located along the length of the conductor on exposed surfaces on the conductor.
 15. The solar panel of claim 14 in which the insulative strip is formed of flexible polymeric material.
 16. The solar panel of claim 15 in which the series of elongate conductors comprise generally flat ribbons of copper material laminated to the insulative strip.
 17. The solar panel of claim 16 in which the flat ribbons of copper material are coated with a layer of solder.
 18. The solar panel of claim 17 in which at least some of the conductors are longitudinally staggered.
 19. The solar panel of claim 18 in which the pattern of conductors include an electrical connection region for electrically connecting to an external device.
 20. The solar panel of claim 19 in which the electrical connection region is at a central location on the buss bar strip.
 21. The solar panel of claim 20 further comprising terminal pads extending from the elongate conductors at the electrical connection region.
 22. The solar panel of claim 21 further comprising a male circular connector soldered to each terminal pad.
 23. The solar panel of claim 22 in which the series of elongate electrical conductors include at least four elongate conductors extending from the electrical connection region, at least two extending on one side, and at least two extending on an opposite side.
 24. The solar panel of claim 23 in which on each side of the electrical connection region, one conductor is shorter than the other.
 25. The solar panel of claim 14 in which the insulative strip is a first insulative strip, the buss bar strip further comprising a second thin elongate flat flexible strip of insulative material laminated to the first strip and over the pattern of conductors, the second strip having access windows at selected locations for providing lateral electrical connection points on the conductors.
 26. The solar panel of claim 14 further comprising lamination materials extending over the buss bar strip.
 27. The solar panel of claim 22 in which the external device is an electrical connector having female terminals that engage the male circular connectors.
 28. A solar panel comprising: a series of solar cells having a series of electrical lines extending therefrom at laterally spaced intervals; and buss bar strip means for conducting electricity mounted to the solar panel adjacent to the series of solar cells and electrically connected to the series of electrical lines extending from the solar cells, the buss bar strip comprising a thin elongate flat flexible strip of insulative material having a longitudinal length, and a predetermined pattern of elongate conductor means for conducting electricity longitudinally disposed on the insulative strip in at least two rows along the longitudinal length and electrically isolated from each other, each conductor means for conducting electricity having a predetermined position, length, and spacing from each other on the insulative strip and laterally electrically connected to selected electrical lines from the solar cells at lateral electrical connection points located along the length of the conductor on exposed surfaces on the conductor.
 29. A method of forming a buss bar strip for mounting to a solar panel for electrically connecting to a series of electrical lines extending from solar cells comprising: providing a thin elongate flat flexible strip of insulative material having a longitudinal length; and disposing a predetermined pattern of elongate conductors longitudinally on the insulative strip in at least two rows along the longitudinal length and electrically isolated from each other, each conductor having a predetermined position, length, and spacing from each other on the insulative strip for laterally electrically connecting to selected electrical lines from the solar cells at lateral electrical connection points located along the length of the conductor on exposed surfaces on the conductor.
 30. The method of claim 29 further comprising forming the insulative strip from flexible polymeric material.
 31. The method of claim 30 further comprising forming the series of elongate conductors from generally flat ribbons of copper material laminated to the insulative strip.
 32. The method of claim 31 further comprising coating the flat ribbons of copper material with a layer of solder.
 33. The method of claim 32 further comprising longitudinally staggering at least some of the conductors.
 34. The method of claim 33 further comprising forming the pattern of conductors to include an electrical connection region for electrically connecting to an external device.
 35. The method of claim 34 further comprising positioning the electrical connection region at a central location on the buss bar strip.
 36. The method of claim 35 further comprising extending terminal pads from the elongate conductors at the electrical connection region.
 37. The method of claim 36 further comprising soldering a male circular connector to each terminal pad.
 38. The method of claim 37 in which the series of elongate electrical conductors include at least four elongate conductors, the method further comprising extending from the electrical connection region, at least two conductors on one side, and at least two conductors on an opposite side.
 39. The method of claim 38 further comprising forming on each side of the electrical connection region, one conductor shorter than the other.
 40. The method of claim 29 in which the insulative strip is a first insulative strip, the method further comprising providing the buss bar strip with a second thin elongate flat flexible strip of insulative material laminated to the first strip and over the pattern of conductors, the second strip having access windows at selected locations for providing lateral electrical connection points on the conductors.
 41. A method of electrically connecting a solar panel, the solar panel including a series of solar cells having a series of electrical lines extending therefrom at laterally spaced intervals, the method comprising mounting a buss bar strip to the solar panel adjacent to the series of solar cells, the buss bar strip comprising a thin elongate flat flexible strip of insulative material having a longitudinal length, and a predetermined pattern of elongate conductors longitudinally disposed on the insulative strip in at least two rows along the longitudinal length and electrically isolated from each other, each conductor having a predetermined position, length, and spacing from each other on the insulative strip and laterally electrically connected to selected electrical lines from the solar cells at lateral electrical connection points located along the length of the conductor on exposed surfaces on the conductor.
 42. The method of claim 41 further comprising forming the insulative strip from flexible polymeric material.
 43. The method of claim 42 further comprising forming the series of elongate conductors from generally flat ribbons of copper material laminated to the insulative strip.
 44. The method of claim 43 further comprising coating the flat ribbons of copper material with a layer of solder.
 45. The method of claim 44 further comprising longitudinally staggering at least some of the conductors.
 46. The method of claim 45 further comprising forming the pattern of conductors to include an electrical connection region for electrically connecting to an external device.
 47. The method of claim 46 further comprising positioning the electrical connection region at a central location on the buss bar strip.
 48. The method of claim 47 further comprising extending terminal pads from the elongate conductors at the electrical connection region.
 49. The method of claim 48 further comprising soldering a male circular connector to each terminal pad.
 50. The method of claim 49 in which the series of elongate electrical conductors include at least four elongate conductors, the method further comprising extending from the electrical connection region, at least two conductors on one side, and at least two conductors on an opposite side.
 51. The method of claim 50 further comprising forming on each side of the electrical connection region, one conductor shorter than the other.
 52. The method of claim 41 in which the insulative strip is a first insulative strip, the method further comprising providing the buss bar strip with a second thin elongate flat flexible strip of insulative material laminated to the first strip and over the pattern of conductors, the second strip having access windows at selected locations for providing lateral electrical connection points on the conductors.
 53. The method of claim 41 further comprising laminating lamination materials over the buss bar strip.
 54. The method of claim 49 in which the external device is an electrical connector having female terminals, the method further comprising engaging the female terminals of the electrical connector with the male circular connectors. 